Collapsible carton and blank



lg! no Sheet W. H. PERKINS COLLAPSIBLE CARTON AND BLANK F/G. I

WILL/AM H. PER/(INS Kmzl. LL). "Fleets ATTORNEY Filed Aug. 22, 1967 March 25, 1969 March 25, 1969 w, PERKlNs 3,434,647

COLLAPSIBLE CARTON AND BLANK Filed Aug. 22,1967 Sheet 2 EARL. (D LOCKS ATTORNEY United States Patent 3,434,647 COLLAPSIBLE CARTON AND BLANK William H. Perkins, Oxford, Ohio, assignor to Diamond International Corporation, New York, N.Y., a corporation of Delaware Filed Aug. 22, 1967, Ser. No. 667,315

Int. Cl. B65d /00, 5/36, 5/46 US. Cl. 229-16 11 Claims ABSTRACT OF THE DISCLOSURE A foldable-flat carton produced from a cut-and-scored blank assembled into a folded-fiat condition prior to erection in which a foldable, staying and reinforcing structure is provided at the carton end Walls, and the carton is maintained in its erected transport condition by such end walls and an improved carton cover-and-handle assembly.

Many different cartons have been developed for the purpose of protectively packaging different commodities. Some requisites of such cartons is to provide an inexpensive readily assembled and erected carton which is folded-flat in a shipped or stored condition, and which, when erected, will be relatively rigid to facilitate ready carrying in transport as well as protecting the goods being packaged.

A primary object of the present invention is to provide a packaging carton which is normally stored in a foldedfiat condition and which can be readily erected, the carton including novel end rigidifying structure unfolding as the carton is erected.

Another object of the present invention in conformance with that set forth above is to provide a novel top flap structure in conjunction with a foldable flat end wall whereby the top flap cooperates with a novel rigidifying structure.

And yet another object of the present invention is to provide a novel top lock flap and carrier handle construction in a foldable fiat carton.

These, together with other and more specific objects and advantages, will become apparent from a consideration of the following description when taken in conjunction with the accompanying drawing forming a part thereof and wherein the drawing:

FIG. 1 is a plan view of a blank from which the novel carton is produced with intermediate portions of the carton side walls being removed;

FIG. 2 is a perspective view, on a reduced scale, of a carton produced from the blank of FIG. 1;

FIG. 3 is an enlarged fragmentary perspective view of the handle of FIG. 2;

FIG. 4 is a sectional view taken on the plane of line 44 of FIG. 3;

FIG. 5 is a fragmentary perspective view of an intermediate portion of the blank of FIG. 1, illustrating an initial folding step during assembly of the folded-flat carton;

FIG. 6 is a fragmentary perspective view of the portion of the carton shown in FIG. 5, and illustrating the final-folding step in assembly of the carton;

FIG. 7 is a fragmentary perspective view of the assembled blank showing the relative position of the elements when erecting the folded-flat carton;

FIG. 8 is a view similar to FIG. 7 illustrating a subsequent position of the elements as the carton is being erected;

FIG. 9 is a perspective view of the partially erected carton, showing the elements in position shown in FIG. 8, but looking into the carton as indicated by the direction arrow on FIG. 8;

3,434,647 Patented Mar. 25, 1969 FIG. 10 is a fragmentary perspective view of the elements shown in FIGS. 7-9, showing the lower left-hand portion of FIG. 2 on an enlarged scale, with a portion broken away to show details;

FIG. 11 is an enlarged fragmentary perspective view showing the upper left-hand corner of the erected carton and demonstrating the manner in which the inner closure flap stabilizes the erected carton; and

FIG. 12 is a fragmentary perspective view of the erected and closed carton showing the relationship of the cooperating staying structure in the end wall and cover of the carton.

The blank of FIG. 1 is produced from any suitable material, i.e. paperboard, cardboard, plastics and/or combinations thereof, which can be die-cut and suitably creased or scored to facilitate folding and unfolding.

Referring to FIG. 1, a blank is indicated generally at 10 and comprises a bottom .panel 12 having score-line side margins 14 and 16 and which is divided by a medial score-line 18 defining panel segments 20 and 22. Hingedly connected to the side margins 14 and 16, respectively, are rectangular side wall panels 24 and 26 which include upper score-line margins 28 and 30, respectively, and to which are hingedly connected top closure panels 32 and 34.

The closure panel 32 includes a pair of longitudinally spaced, die-cut, female slots 35 extending transversely through the closure panel 32. The closure panel will be disposed beneath closure panel 34 when the carton is erected and closed.

A loosely-looped displaceable handle 36 is secured at opposite ends 38 to the undersurface of closure panel 32 and the handle 36 will be drawn through the closure panel 34 as will subsequently become apparent.

The closure panel 34 will be the outermost panel when the carton is closed and includes in its free edge 40, 0pposite hinge line 30, longitudinally spaced male lock tabs 42, flanking a central abutment panel portion 44. Extending longitudinally of closure panel 34 and formed in abutment panel portion 44 is a displaceable panel element 46 hingedly connected along edge 48 to panel portion 44 and being die-cut about its remaining margin. Formed by a pair of parallel elements extending longitudinally from terminal ends of the panel element 46 are retention tabs 50 which will align with the ends of the looped, displaceable handle 36 as seen in FIG. 3 i.e., after the looped handle was pulled through the aperature formed by the panel element 46.

The bottom panel 12 is marginally defined at opposite ends by fold or score lines 52 and 54 colinear with suitably scored fold lines 56 and '58 and 60 and 61, respectively, defining the ends of the side walls 24 and 2.6.

Hingedly connected at opposite ends of the bottom panel 12 i.e., panel segments 20, 22, and side wall panels 24 and 26, are end wall element-arrays 62 and 64. Since the end wall element arrays are substantially mirror images of each other, only one of these arrays will be described in detail and the other will be identified by similar, primed reference numerals.

The end wall element array 62 comprises a bottom, gusset-fold section defined by score or fold lines '68 and 70, respectively, colinear with fold lines 14 and 16. The gusset-fold section includes wing elements 72 and 74, respectively, connected to the end of panel segments 20 and 22, and being separated by a free margin formed by a V-shaped notch 75 diverging from the terminal end of fold line 18. Extending from the intersection of fold lines 52, 68 and 52, 70 are angular fold or score lines 76 and 78 which extend toward each other and into the V-shaped notch at about a 45 angle with respect to the intersection of the fold lines. The score lines 76 and 78, respectively define gusset web segments 80, 82 and 84, 86. Diverging at a greater angle from the outer end of V-shaped notch 75, generally at the terminal end of the fold lines 76 and 78 are free margins 88 and 90, respectively. The margin 88 is disposed at a sharper angle than margin 90 and thus, segment 80 has a slightly lesser area than segment 84. This provides a relief portion facilitating unfolding movement of the gusset fold sections into the erected carton position as will be described.

Hingedly connected at one side to fold line 56 and at its lower margin 70 to web segment 84 is an outer end Wall panel element 92. Hingedly connected to the upper margin of side wall panel element 92 at a fold line 94, colinear with fold line 30, is a closure flap 96. The closure flap 96 is separated by a die-cut from the adjacent side margin of closure panel 34.

The closure flap 96, side wall panel element 92 and web segment 84 have extending therethrough a score or fold line 98 which permits the assembled blank to be folded flat as seen, for example, in FIGS. 6 and 7. The score or fold line 98 defines in the closure flap 96 segments 100, 102, defines in the side wall panel element 92 segments 104, 106, and in the web segment 84 defines generally triangular segments 85, 87.

Hingedly connected to fold line 58, and at its lower margin 68 to web segment 80 is an inner end wall, reinforcing or staying element 108. The element 108 has hingedly connected at its upper margin 110, which is colinear with fold line 28, a closure flap 112 which is separated from top closure panel 32 by a die-cut margin.

The blank of FIG. 1 is generally rectangular and thus, a minimum amount of scrap results during its production, and the generally regular shape lends itself to ready layout.

Assembly carton to folded flat condition When assembling the blank 10, see FIG. 5, the end wall element array 62 (and corresponding array 64) -is first manipulated as follows: The wing element 72, inner and staying element end wall 108, as well as closure flap 112 (not shown) are folded at line 54 onto respective adjacent portions of the bottom panel Segment 20, side wall panel 24 and closure panel 32. Likewise, the wing element 74, outer end wall 92 and closure fiap 96 are folded at line 56 onto adjacent portions of bottom panel segment 22, side wall panel 26 and closure panel 34. The now exposed overfolded portion of end wall panel segment will have glue applied thereto, or will have pre-applied glue thereon, and will be suitably secured to end wall panel segment portion 107, as indicated by phantom lines in FIG. 5, when the blank is assembled.

Referring to FIG. 6, the two blank halves, which are generally symmetrical about fold line 18 in the bottom panel, will be folded onto each other and this constitutes assembling of the blank into a folded fiat condition.

In the folded flat condition, the assembled carton can be readily stacked and stored, however, the cartons can be readily erected into a relatively rigid and stable rectangular cube which protects packaged merchandise, and which can be readily carried without collapse of the carton or damage to the contents.

Erection of the assembled carton Referring to FIG. 7 when opening the container, the inner end wall 108 adhesively attached to panel segment 106 will pivot about hinge line 58 toward the end of the carton; see FIGS. 8 and 9. At the same time, the panel segments 104 and 106 pivot toward coplanar relation as the inner wall element 108 pivots into staying relation behind elements 104, 106 to rigidly brace the end walls.

Additionally, as the inner and outer end wall elements move toward overlying relation, the bottom panel segments 20, 22 hinged at fold line 18 move toward coplanar relation. Web segments 82, 86 hinged to the ends of bottom panel segments, and overlying the same after assem- 4 bly of the blank, also move upwardly with the segments 20, 22.

Likewise, the triangular web segments 85, 87 at the hinge line 70 move outwardly and downwardly onto the web segments 82 and 86, respectively. As the inner end wall element 108 is pivoted, the web segment hingedly connected at 68 to the lower edge thereof, is folded over web segments 82, 86; see FIG. 9 and 10. Edge 80 is cut away 'at one end to provide relief to enable the web segments to unfold in the manner illustrated and described.

Referring to FIGS. 10 and 11, the lower ends of the assembled carton are illustrated. Note the inner end wall 108 extends in a single uninterrupted plane behind the unfolded, coplanar outer end wall segments 104, 106. Additionally, since the web segment 80 is distorted when folded onto segments 82, 86, this provides a toggle-like lock action whereby the lower end walls are positively erected and substantially retained in this condition.

The upper end is stayed or reinforced by the inwardly folded closure flap 112 upon which the medially foldable top closure flap segments 100, 102 will overlie.- Thus, the inner end wall 108 reinforces and prevents collapsing of the end walls about fold line 98, and the right angularly disposed closure flap 112 prevents collapsing of the end walls adjacent the top of the closed carton. Additionally, the unfolded and overlying web segments deter reorientation of the elements to a folded fiat condition.

After the end closure flaps 96, 112 are oriented inwardly in the manner described above, the top closure panel 32 is pivoted at hinge line 28 onto the closed end flaps. The top panel 34 is pivoted at hinge line 30 onto the panel 32. The looped handle 36 is pushed through the aperture produced by panel element 46 by displacing the panel element 46 about its hinge line 48. After the handle is pulled through the aperture, the panel element 46 is once more positioned into the plane of panel 34 and the lower ends of the handle are frictionally gripped at tabs 50. The male tabs 42 will be positioned in the female slits 35 in top panel 32 and the closed carton is in a condition for ready transport without collapse.

It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification.

What is claimed is:

1. A foldable-fiat carton produced from a one-piece blank comprising:

opposed side walls hingedly connected at lower edges to a bottom panel disposed therebetween,

said bottom panel including a medial fold line forming similar bottom panel segments; and

end wall element-arrays hingedly connected to opposite ends of said bottom and side walls, said arrays comprising an end wall element hingedly connected to said side walls and extending the length thereof, gusset fold segments hingedly connected between lower edges of said end wall elements and said bottom panel segments and being spaced from each other at the medial fold line of said bottom panel,

said gusset fold segments being hingedly connected at one side to each other and respectively hingedly connected at another side to a bottom panel segment and end wall element, one end wall element including a medial fold line parallel to the side margin thereof, the other end wall element being planar and substantially rigid,

said other end wall element comprising an inner wall element and including an upper closure flap hingedly connected to the upper edge of said end wall element, said inner wall element and closure flap each being planar and rigid for preventing movement of said carton side walls toward each other when the carton is erected.

2. The structure as claimed in claim 1 in which said one end wall element includes a closure flap hingedly connected to the upper edge thereof and medially divided into closure flap segments positionable in overlying relation onto said inner end wall closure flap of said other inner wall element.

3. The structure as claimed in claim 1 in which said gusset fold segments are spaced from each other by a V- shaped notch diverging from the terminal end of the medial fold line of said bottom panel.

4. The structure as claimed in claim 3 in which said V-s'haped notch terminates generally at the medial portion of said end walls, said gusset fold segments being triangular and including afree margin diverging angularly away from the terminal end of said V-shaped notch.

5. A foldable-flat carton produced from a one-piece blank comprising: a bottom panel, side wall panels hingedly connected at lower edges to said :bottom panel disposed therebetween; end wall element-arrays hingedly connected to opposite ends of said bottom and side walls,

said end wall element-arrays and bottom panel including portions permitting said opposed side walls to be disposed in overlying, folded-flat relationship; and means for closing the top of the carton when erected comprising:

closure flaps hingedly connected to an upper portion of said end wall element-arrays and extending between said side walls when spaced from each other in the erected carton, top closure panels hingedly connected to upper marginal portions of the respective side walls and disposed in overlying relationship to said inwardly folded closure flaps and each other, one of said top closure panels including at least one female slot portion therein, said one top closure panel including at integral handle projecting out of the plane thereof;

said other top closure panel including at least one male lock tab removably received in said female slot portion and an aperture portion for receiving said handle therethrough.

6. Structure as claimed in claim 5 in which said one top closure panel includes a second female slot portion spaced from said first-mentioned female slot portion, said slot portions flanking said handle, said other top closure panel including a pair of male lock tabs disposed on opposite sides of said apertured portion.

7. The structure claimed in claim 6 in which said lastmentioned aperture includes a displaceable flap flanked on opposite sides by retention tabs struck from said other top closure panel, said displaceable handle comprising a loop element integrally connected to said one closure panel and frictionally engaged between said displaceable flap and said retention tabs.

8. A blank for producing a foldable-flat carton comprising: a one-piece element cut-and-scored to form said foldable-fiat carton; said element including: a rectangular bottom panel having end and side margins, a medial fold line extending from end-to-endin said bottom panel and defining bottom panel segments therein; rectangular side wall panels hingedly connected to the side margins of said bottom panel segments and including end and top margins; top closure panels hingedly connected to top margins of said side walls; and

end wall element-arrays hingedly connected to the end margins of said side wall panels and said bottom panel segments, said end walled element-arrays comprising: end wall elements hingedly connected at one side of said side wall panels and having upper and lower marginal fold lines, a gusset-fold section including segments hinged to each other on a diagonal fold line extending from corners of said bottom panel, said diagonal fold lines being spaced from each other by a notch diverging from the medial fold line of said bottom panel, said segments having one side respectively hinged to the end of a bottom panel segment and arfEnd wall element, one end wall element being planaia'and substantially rigid, the other end wall element including a medial fold line parallel to the end margin of the side wall to which it is attached and defining end wall element segments and subdividing the segment at the end of said other end walLgelernent into supplemental segments, said one endw'all element including a planar rigid closure flap for staying the carton top closure panels when the carton is erected and closed. 9. The blank as claimed in claim 8 in which one of said top wall panels includes a displaceable, looped handle,

the other the top closure panel including a displaceable,

flap hingedly connected thereto, a pair of retention tabs flanking said displaceable flap for engaging opposite ends of said loop handle when the carton is erected and closed.

10. The 'blank as claimed in claim 9 which said one top closure panel includes spaced, intermediate slot portions flanking said handle, saidother top closure panel including free male lock tabs extending from one side margin thereof and flanking said displaceable flap for removal receipt in said slot portions.

11. The blank 'as claimed in claim 8 in which said other end wall element includes a closure flap hingedly connected to said other end wall element and through which said medial fold line 'eXtends defining therein adjacent closure fiap'segments.

References Cited UNITED STATES PATENTS 

